Mechanical system for power change between the input and output thereof

ABSTRACT

The system includes at least two power disc elements, each mounted for rotation on a central shaft which is typically fixed. The first power disc element includes a first peripheral gear portion at the rim of the power disc element by which the first power disc element is turned. A first system gear mounted on a first system shaft mates with the first peripheral gear portion with first system shaft being offset from the central shaft. The first power disc element also has a second peripheral gear portion in the vicinity of the rim extending forwardly of the first power disc element. A second power disc element has a plurality of outer drive gears mounted for rotation to a rearwardly facing surface, positioned to mate with the second peripheral gear portion on the first power disc element. A central gear is fixed to the central shaft and mates with the outer drive gears on the second power disc element. A second system gear mates with a peripheral gear portion of the second power disc element, with the second system gear mounted on a second system shaft which is also offset from the central shaft.

TECHNICAL FIELD

This invention relates generally to a system for supplying power at anoutput in response to an input source thereof, and more particularlyconcerns such a system which produces a power change between the inputand outputs thereof.

BACKGROUND OF THE INVENTION

The generation of power, and correspondingly, machines which use powerto produce work, such as by the turning of a shaft by electric power,are quite important to modern industry and society. Electric power isused to run a large number of machines which vary substantially inoutput capability, depending upon the task, from less than onehorsepower to several thousand horsepower and even greater, toaccomplish specific tasks. Electric power is also used to power electriclights and many electric appliances.

The sources of electric power also vary widely, including large electricpower generating plants using, for instance, hydroelectric capability,fossil and/or nuclear fuels, among others. Electric power produced bysuch plants is then supplied to individual users, through large, complexand expensive transmission and distribution systems. Power is lost inthe transmission and distribution system. Alternatively, small,stand-alone electric power sources such as electric generators or microturbines, which are typically run by fossil fuel (gasoline) engines,natural gas turbines or other similar devices, are capable of supplyingsmall amounts of power for specific users. These generators are also not100% efficient.

Electric motors are also less than 100% efficient, as are systems usingelectric power directly, such as lighting systems. Some energy is lostin carrying out specific work, i.e. turning a shaft or lighting afilament in a bulb, for instance. Efficiencies of modern electric motorscan be quite high, however, exceeding 90%. It is desirable that electricmotors or similar devices have efficiencies as high as possible, andfurther, it is desirable to produce electric power using as littleenergy as possible. Historically, it has been a goal to actually be ableto increase electric power from input to output, although this has notbeen heretofore realized.

Furthermore, it is highly desirable to have a capacity of local sourcesof electric power, particularly inexpensive power, independent ofexisting power distribution systems, without the requirement of largesupplies of fuel, such as fossil fuel in particular. One example is forpowering irrigation systems in, for instance, third world countries,where the cost of energy to run such systems adds significantly to thecost of food production. Economic electric-powered vehicles are alsodesirable and are another example where system improvements would beadvantageous to the environment.

SUMMARY OF THE INVENTION

Accordingly, the present invention includes at least two power discelements mounted for rotation about a central axis, wherein the firstpower disc element includes a first peripheral portion in the vicinityof the rim thereof by which the first power disc element is turned; afirst system gear, mounted on a first system shaft which is offset fromthe central axis; wherein the first power disc element has a secondperipheral gear portion in the vicinity of a forwardly extending rimportion of the power element, and wherein the second power disc elementhas a plurality of outer drive gear members rotatably mounted to a rearsurface thereof and positioned so as to mate with the second peripheralgear portion on the first power element; a central gear which is mountedso as to be fixed relative to the central axis and which is furthermounted to mate with the outer drive gears on the second power discelement, such that rotation of the first system gear by a motor resultsin rotation of the first and second power disc members; and a secondsystem gear mating with a peripheral gear portion of the second powerdisc element, located in the vicinity of the rim of the second powerdisc element, the second system gear mounted on a second system shaftwhich is offset from the central axis, wherein in operation a powerchange results between first and second system shafts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of the power system of the present invention.

FIG. 2 is a side elevational view of the system of the presentinvention.

FIG. 3 is an exploded view of a portion of the system of the presentinvention.

FIG. 4 is an exploded view of another portion of the system of thepresent invention.

FIG. 5 is an exploded view of another portion of the system of thepresent invention.

FIG. 6 is a diagram of an application of the system of the presentinvention involving a vehicle.

BEST MODE FOR CARRYING OUT THE INVENTION

The system of the present invention, shown generally in one embodimentat 10 in FIG. 1, produces an efficient power change between the inputand output ends of the system. The system, generally shown at 10, isdriven by a conventional electric motor 12 at one end of the system 10in FIG. 1. In the embodiment shown, electric motor 12 is relativelysmall, i.e. a two horsepower, single-phase motor, operating at 110volts. However, it should be understood that the input motor could besignificantly larger and/or could be a three-phase motor operating at220 volts. The characteristics of the drive motor are not critical tothe present invention.

Electric motor 12 includes a conventional output shaft 14, also referredto herein as a system input power shaft, which extends through a firstfixed support bracket 16. Support bracket 16 supports the present powersystem at one end thereof and extends upwardly from a base supportmember 18 (FIG. 2). At the other end of the system 10 is a secondsupport bracket 20. The support arrangement (elements 16, 18 and 20 inthe present system) can vary widely in configuration and structure,depending upon the particular arrangement of the power system 10 itself.

Referring now to FIGS. 1-5, mounted on the free end of system inputpower shaft 14 of electric motor 12 is an input drive gear 24. In theembodiment shown, input drive gear 24 drives an input power disc 26. Theinput power disc 26 in the embodiment shown is circular, approximately18 inches in diameter, and includes a central portion 28 with a centralaxial opening 30 and a rim portion 32 which extends perpendicularly fromcentral portion 28 both from a rear surface 33 of central portion 28 andan opposing forward surface 35 of the central portion. In the embodimentshown, the rim portion in both rear and forward directions isapproximately 2½ inches wide, with first and second sets of gear teeth34, 36 on the inner surfaces of rear section 37 and the forward section39 of the rim portion 32.

The input drive gear 24 in the embodiment shown is 6 inches in diameter,has 66 teeth and is positioned to mate with gear teeth set 34 on therear section 37 of rim portion 32 of the input power disc 26, becausethe output shaft 14 of the motor 12 is offset from the center of theinput power disc 26.

The input power disc 26 is mounted for rotation on a main shaft 38,which is also supported at opposing ends thereof by supporting brackets16 and 20. Power disc 26 is mounted by a key 39 on shaft 38 to a bearing40 which is positioned in axial center opening 30 in the central portionof the power disc. The keying of the central shaft to bearing 40 is notcritical but does reduce possible wear due to undesired rotation of thebearing. Bearing 40 in this embodiment does not rotate, but permitsinput power disc 26 to rotate freely on the bearing relative to the mainshaft. As discussed below in more detail, in some arrangements, mainshaft 38 can rotate to some extent to achieve particular system results.

In operation, shaft 14 from motor 12 will rotate the input drive gear24, which will rotate the input power disc 26 about main shaft 38, inparticular bearing 40. The speed of rotation of the input power disc 26depends upon the rotation of shaft 14 and the relative size ratiobetween input drive gear 24 and power disc 26 (with the gear set 34 oninput power disc 26 being at its rim). For instance, if the power shaft14 rotates at 1786 rpm (the rating of motor 12), when input drive gear24 is 6 inches in diameter and power disc 26 is 18 inches in diameter(3:1 ratio), the first power disc will rotate at 595⅓ rpm.

A first intermediate power disc 42 follows input power disc 26, and isalso mounted on main shaft 38 through bearing 43, which is keyed to mainshaft 38. The first intermediate power disc 42 has a flat rear surface44 and a rim portion 46 which extends in the forward direction. Rimportion 46 is identical to the forward section 39 of rim portion 32 oninput power disc 26. The first intermediate power disc 42 is otherwisesubstantially identical to input power disc 26, having the samediameter, configuration and structure thereof, and mounted for rotationon main shaft 38 through bearing 43.

Rotatably mounted to rear surface 44 of first intermediate power disc 42are three equally spaced outer drive gears 50, 52 and 54. Each of theouter drive gears 50, 52 and 54 are also 6 inches in diameter and have66 teeth around the periphery thereof, in the embodiment shown. Thegears 50, 52 and 54 are mounted for rotation by bolts 60—60 and bearings62—62. The outer drive gears 50, 52 and 54 are free to rotate inoperation about their individual associated bearings 62—62 on bolts60—60. As a possible alternative structure, there could be two or evenjust one outer drive gear. Speed of operation may be limited,particularly with just one gear, and the mounting structure might haveto be modified to some extent. Mounted at the center of rear surface 44between, and meshing with, outer drive gears 50, 52 and 54 is a centralgear 64, which in the embodiment shown is substantially identical toouter drive gears 50, 52, 54.

Central gear 64 is in the same plane as outer gears 50, 52 and 54.Central gear 64 is keyed to main shaft 38, as are power discs 26 and 42;hence, if main shaft 38 does not rotate, neither does central gear 64,while if main shaft 38 in a particular arrangement does rotate aselected amount, central gear 64 will move therewith. Additionalwashers, spacers and/or shims may be added to the system, such as foralignment or wear purposes, but are not critical to the invention.

In the embodiment shown, input power disc 26 and the first intermediatedisc 42 are made from steel. The central portion of the input power discis approximately 1½ inches thick, while the central portion of theintermediate power disc is approximately 2 inches thick. The rim portionof input power disc 26 is approximately 2½ inches thick, while the rimportion of intermediate power disc 42 is also approximately 2½ inchesthick. It should be understood, however, that the power discs can bemade in different sizes, with different materials, including aluminumand even various plastics, which will change the overall weight of thesystem. Further, while there are three outer drive gears shown, in someconfigurations there could be two outer drive gears, or in some cases,more than three. In addition, while the outer drive gears are shown tobe the same size as the central drive gear in the embodiment shown, itis possible that the central drive gear could be a different size fromthe outer drive gears. Also, while the input drive gear is one-third thesize of the input power disc, in the embodiment shown, a different ratiocould be used.

The first intermediate power disc 42 is positioned on shaft 38 relativeto the input power disc 26 such that the forward edge 45 of rim portion32 of input power disc 26 is spaced slightly apart from rear surface 44of the first intermediate power disc, permitting free rotation thereof,but further such that outer drive gears 50, 52, and 54 on intermediatepower disc 42 mesh with gear set 36 on the forward section 39 of rimportion 34 of input power disc 26.

In operation, the rotation of input power disc 26 caused by the drivingaction of input gear 24 will result in rotation of the outer drive gears50, 52 and 54 about their associated mounting bolts, and throughmechanical interaction with central gear 64 will initiate rotation ofthe first intermediate power disc 42. The first intermediate power disc42, the three outer drive gears 50, 52 and 54, and associated mountingbolts and bearings and the central gear 64 keyed to main shaft 38 form afirst intermediate power disc assembly.

Successive power disc assemblies, identical to the first power discassembly in this embodiment, are positioned successively along mainshaft 38, with each intermediate power disc assembly interacting withthe next successive power disc assembly by the mating of the gear set onthe forward rim section of one intermediate power disc with the threeouter drive gears in the next successive intermediate power discassembly. Thus, in the arrangement shown, the rotation of eachintermediate power disc will produce rotation of the next intermediatepower disc, with the rotation (rpm) speed of each intermediate powerdisc being approximately one-third lower than that of the previous powerdisc.

In the embodiment shown in FIG. 1, there are four intermediate powerdisc assemblies. Following the last intermediate power disc assembly inthe system of the present invention is an output power disc 70, which isbasically identical to the power disc in the several intermediate powerdisc assemblies. An output or takeoff gear 74 is mounted on a powershaft 76 of another electrical device, such as for instance a generator78, positioned at the output end of system 10. Generator 78 can produceelectricity. Power shaft 76 is offset from the main drive shaft 38 uponwhich the individual power discs are rotatably mounted, similarly to theoffset of the system input power shaft 14 of motor 12 relative to themain shaft 38. The output gear 74 is in the embodiment shownsubstantially identical to the input gear 24 in configuration, size andthe number of teeth, and is positioned to mate with the gear set on theinternal surface of the rim of the power disc 70. A 3:1 ratio thusexists between output power disc 70 and output gear 74, such that outputgear 74 has an rpm of three times that of the power disc 70.

In operation, electric motor 12 will drive the system of the presentinvention at steady-state following a relatively short start-up, duringwhich all of the power discs are brought up successively to steady-statespeed. Output/takeoff gear 74 will rotate power shaft 76, drivinggenerator 78 to produce an electric power output.

It should be understood that the arrangement of FIG. 1 is only oneembodiment. For instance, in the arrangement of FIG. 1, the inputelectric motor 12 located at one end of the system results in an outputshaft rpm which is less than that of the rpm of the motor, assuming thatthe input and output gears are the same size, i.e. each successive powerdisc from the electric motor end to the generator end of the systemturns at a decreased speed (⅓ less) than the previous power disc. Themotor and the generator, however, could be reversed, such that the speedof the output shaft is greater than the speed of the input electricmotor shaft, with an approximately ⅓ increase in speed for eachsuccessive power disc assembly in the system. The system of the presentinvention can be operated advantageously in both directions. In such acase, the output/takeoff gear would be the input gear, driven by themotor, and the input gear would be the takeoff gear, driving a generatoror similar device.

Further, while the input gear and the output/takeoff gears mate,respectively, with gear sets on an internal surface of the rims of theinput and output power discs, it should be understood that the inputdrive gear and the output takeoff gear can mate with a gear set on anexterior surface of the rim portion. Hence, gear sets on the internalsurfaces of the rim portions of the input and output power discs are notessential to the invention. Other arrangements could be used forproviding input power to the system of taking power from the system,including a sprocket drive gear or other means, including belts orfluids or magnetic systems.

Still further, while the arrangement shows a total of four intermediategear assemblies, a greater or lesser number can be used, depending uponthe amount of power change/advantage desired. At a minimum, however,there must be an input power disc assembly and an output power discassembly providing a first level of power change/advantage. In such aminimal arrangement, the four intermediate discs shown in FIG. 1 wouldbe eliminated, with the output power disc assembly mating directly withthe input power disc assembly. There also could be arrangements wherethere are more than four intermediate power discs, with each additionalpower disc assembly being identical to the power disc assembly shown,with the total number of disc assemblies being dependent upon the degreeof power/change advantage between the input and output desired.

A number of factors influence the operation and the amount of powerchange/advantage of the above system. For instance, the relative sizedifference between the outer drive gears, the size of the power disc towhich they are rotatably mounted, and the size of the central drive gearall affect the power change/advantage and/or the speed increase/decreaseof the rotation of the successive power discs in the system.

As indicated above, the central shaft in the embodiments shown typicallyremains fixed, so that the central gear does not rotate in operation ofthe system. The rotational arrangement and interaction of the outerdrive gears and the central gear on the one surface of the power discresults in a force/pressure on the mounting bolts holding the outerdrive gears, such that the power disc on which the outer drive gears aremounted begins to rotate in response to rotation of the previous powerdisc and the mating of its rim gear with the outer drive gears. Themounting shaft can, however, be allowed to rotate to some extent in onedirection at startup. The overall power change/advantage of the systemwould be decreased, depending upon the amount of rotation of themounting shaft, but startup of the system would be more efficient andtake less time.

Further, the mounting shaft and the central gear thereon could be madeto rotate slightly in the opposite direction from the power discs, whichwould increase the power gain from one stage to the other. Typically,there must be a substantial difference between the rotational speed ofthe outer drive gears and the central gear.

Also, the embodiment shown has a gear ratio of 3:1 between the initialdrive gear and the input power disc and a 1:3 ratio between the outputpower disc and the output/takeoff gear. While these ratios can bevaried, change will affect the power advantage. Further, in some casesthere may be an additional gear or gears at the output to increase thespeed of the output shaft. Since traditional gear system ratios affectpower output when they are a part of the input or output of the system,consideration must be given to the specific power requirements of eachapplication. A gear ratio which is too high, for instance 10 times, maynegatively affect the power efficiency/advantage of the system.

Hence, a mechanical system has been disclosed which provides a highpower efficiency or power advantage from the input end to the output endthereof. The system can be arranged such that the output speed of thesystem is higher or lower than the input speed (i.e. the motor speed).Further, as shown above, various arrangements can be utilized to producespecific desired results.

FIG. 6 shows a vehicle application for the system of the presentinvention. The vehicle 200 includes a conventional AC electric motor202, which is run by a vehicle battery 204 through an inverter 206 whichis part of the vehicle control system, which produces the required ACvoltage to run motor 202 from a DC voltage provided by the battery. Theoutput of motor 202 is applied to a system of the present invention,shown generally at 208, which results in a power advantage, the outputof which is applied to a conventional generator 210. One output fromgenerator 210 is applied to a charger 212 in the control system, whichcharges the vehicle battery 204, which in turn then continues to run theengine 202. This circuit provides the electric power for the vehicle.

The other output from generator 210 is directed to a second electricmotor 214, the output of which is applied as a drive to a second powersystem of the present system 216. Power system 216 provides anotherpower advantage used to drive the vehicle in standard use bytransmission 218. The system of FIG. 6 can be a self-sustaining vehiclesystem, requiring minimal if any additional power, due to the use of thetwo onboard power systems of the present invention 208 and 216. In casebattery 204 needs an additional power recharge on occasion, conventionalsources of electric power can be used for such recharging. However, evenif such recharging is necessary from time to time, the vehicle of FIG.10 using the present invention is still extremely efficient, relative tothe electric power use from the conventional power grid required by aconventional electric car.

The control system can manage the power generated by the generator 210and direct it as needed to the charging system for the battery 204 orthe second electric motor 214. Since the power system 208 will typicallybe operated at full speed, power could be directed to charging thebattery when the vehicle is stopped. The size and scale of thecomponents could be optimized for various uses and vehicles.

It should also be understood that various intermediate gears can beincorporated between each power disc assembly in order to change gearratios, speed or size of the next power disc. Also, while the powerdiscs shown herein are round, the discs may have shapes other thanround.

Although a preferred embodiment has been disclosed for purposes ofillustration, it should be understood that various changes andmodifications and substitutions could be made in the preferredembodiment without departing from the spirit of the invention as definedby the claims which follow:

What is claimed is:
 1. A mechanical power system, comprising: at leasttwo power disc elements mounted for rotation about a central axis,wherein the first power disc element includes a first peripheral gearportion in the vicinity of the rim thereof by which the first power discelement is turned; a first system gear, mounted on a first system shaftwhich is offset from the central axis for turning the first power discelement; wherein the first power disc element has a second peripheralgear portion in the vicinity of a forwardly extending rim portionthereof, and wherein the second power disc element has a plurality ofouter drive gear members rotatably mounted to a rear surface thereof andpositioned so as to mate with the second peripheral gear portion on thefirst power disc element; a central gear which is mounted so as to befixed relative to the central axis and which is further mounted to matewith the outer drive gears on the second power disc element, such thatrotation of the first system gear results in the rotation of the firstand the second power disc members; and a second system gear mating witha peripheral gear portion of the second power disc element, located inthe vicinity of the rim of the second power disc element, the secondsystem gear mounted on a second system shaft which is offset from thecentral axis, wherein in operation a power change results between firstand second system shafts in operation of the mechanical power system. 2.The system of claim 1, wherein the first and second power disc elementsare mounted for rotation on a central shaft and the central gear isfixed to the central shaft.
 3. The system of claim 1, wherein theplurality of outer drive gears comprise three outer drive gears,approximately all the same size.
 4. The system of claim 3, wherein thecentral gear is approximately the same size as the outer drive gears. 5.The system of claim 1, wherein the first and second power disc membersare circular and have a diameter approximately three times the diameterof the outer drive gears and the central gear.
 6. The system of claim 2,wherein the central shaft is fixed.
 7. The system of claim 1, whereinthe first peripheral gear portion is on an interior peripheral rimsurface of the first power disc member and wherein the peripheral gearportion of the second power element is on an interior peripheral rimsurface of the second power member.
 8. The system of claim 1, whereinthe first peripheral gear portion is on an exterior peripheral rimsurface of the first power disc member.
 9. The system of claim 7,wherein the peripheral gear portion of the second power disc member ison an exterior rim surface thereof.
 10. The system of claim 1, whereinan electric motor drives the first system shaft and the second systemshaft drives an electric power generator.
 11. The system of claim 1,wherein the second system shaft is driven by an electric motor and thefirst system shaft drives an electric power generator.
 12. The system ofclaim 1, wherein the second power disc element, the outer drive gearmembers and the central gear define a power disc assembly, and whereinthe system includes a plurality of power disc assemblies between thefirst and second power disc elements.
 13. The system of claim 9, whereinsaid two power disc elements, said plurality of outer drive gear andsaid central gear define a first power system assembly, and wherein saidpower system comprises a plurality of power system assemblies, arrangedso that a second power disc element of each power system assembly drivesthe first power disc element of a next successive power system assembly,by mating of the peripheral gear portions on said power disc elements.14. The system of claim 1, including a first electric motor driving thefirst system shaft of a first power system, a battery and invertercircuit for powering the first electric motor, a charging system for thebattery, an electric power generator powered by the first power system,the generator providing electric power to the charging system, a secondelectric motor powered by the electric power generator, a second powersystem driven by the second electric motor, and a vehicle transmissiondriven by the second power system, the transmission being adapted todrive a vehicle.
 15. A mechanical power system; comprising: at least twopower disc elements mounted for rotation on a central shaft, wherein afirst power disc element includes a first gear portion by which thefirst power disc element is turned, wherein the first power disc elementhas a second forwardly extending gear portion in the vicinity of a rimportion thereof, and wherein a second power disc element has a pluralityof outer drive gear members rotatably mounted to a surface thereof,positioned to mate with the second gear portion of the first powerelement; and a central gear which is fixed to the central shaft andmates with the outer drive gears on the second power disc element, suchthat rotation of the first power disc element results in rotation of thesecond power disc element, and transfer of power to the second powerdisc element, wherein the second power disc element has a gear portionin the vicinity of a rim portion thereof for driving a takeoff assembly,wherein in operation a power change results between the first and secondpower discs.
 16. The system of claim 15, including a first system gear,mounted on a first system shaft which is offset from the central shaft,for driving the first power disc element, and wherein the takeoffassembly includes a second system gear, mounted on a second system shaftwhich is offset from the central shaft.
 17. The system of claim 15,wherein the plurality of outer drive gears comprise three outer drivegears, approximately all the same size.
 18. The system of claim 17,wherein the central gear is approximately the same size as the outerdrive gears.
 19. The system of claim 15, wherein the first and secondpower disc members are circular and have a diameter approximately threetimes the diameter of the outer drive gears and the central gear. 20.The system of claim 15, wherein the first peripheral gear portion is onan interior peripheral rim surface of the first power disc member, andwherein the peripheral gear portion of the second power element is on aninterior peripheral rim surface of the second power disc member.
 21. Thesystem of claim 15, wherein the second power disc element, the outerdrive gear members and the central gear define a power disc assembly,and wherein the system includes a plurality of power disc assembliesbetween the first and second power disc elements.
 22. A mechanical powersystem, comprising: at least two power disc elements mounted forrotation on a central shaft, wherein a first power disc element includesa first gear portion by which the first power disc element is turned,wherein the first power disc element has a second forwardly extendinggear portion in the vicinity of a rim portion thereof, and wherein asecond power disc element has at least one outer drive gear memberrotatably mounted to a surface thereof, positioned to mate with thesecond gear portion of the first power element; and a central gear whichis fixed to the central shaft and mates with the outer drive gear on thesecond power disc element, such that rotation of the first power discelement results in rotation of the second power disc element, andtransfer of power to the second power disc element, wherein the secondpower disc element has a gear portion in the vicinity of a rim portionthereof for driving a takeoff assembly, wherein in operation a powerchange results between the first and second power discs.